Partially Decomposed Catalyst for Dimethyl Carbonate Synthesis
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Solution Overview
Problem
Current methods for producing dimethyl carbonate from hydrocarbons face challenges such as the corrosive nature of catalysts and incomplete conversion, leading to difficulties in downstream processing and low selectivity.
Innovation Solution
A process involving the partial decomposition of an organic metal complex catalyst supported on silica, using a radical initiator to oxidize hydrocarbons, which maintains at least 5% of the organic compound, specifically utilizing L-arginine and metal-based compounds like copper and nickel, to enhance conversion and selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If copper and bromine catalysts are used for oxidative carbonylation of methanol, then dimethyl carbonate can be produced, but the catalysts are corrosive and cause incomplete conversion
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by using organic metal complexes (such as copper or nickel complexes with organic ligands) instead of traditional inorganic copper and bromine catalysts. This parameter change maintains catalytic activity for high conversion rates while eliminating the corrosiveness associated with traditional catalysts.
Solution Approach 2:
The patent employs composite catalyst materials consisting of metal complexes combined with organic ligands and supported on porous materials. This composite approach creates a catalyst that integrates the catalytic activity needed for high conversion with the structural properties that reduce corrosion and improve stability.
2Productivity
If traditional catalysts are used for hydrocarbon oxidation, then the process can proceed, but selectivity is low and incomplete conversion occurs
Solution Approach 1:
The patent applies local quality by using selectively porous support materials (such as zeolites or activated carbon) that provide specific surface areas and pore structures. This creates localized active sites with optimized properties for promoting desired oxidation reactions while suppressing unwanted side reactions, thereby improving selectivity.
Solution Approach 2:
The patent modifies the catalyst's chemical and physical parameters by using organometallic complexes with specific ligands and controlling the decomposition conditions. These parameter changes enable the catalyst to achieve both high conversion rates and high selectivity for the desired oxidation products.
3Productivity
If complete decomposition of the organic metal complex is achieved, then catalyst activity is maximized, but the organic compound stability is compromised
Solution Approach 1:
The patent deliberately applies partial decomposition of the organic metal complex during catalyst preparation. By controlling the decomposition process to leave some organic compound remaining (at least 5% of the organic compound remains), the catalyst achieves optimal balance between activity and stability. This partial action avoids complete decomposition while still providing sufficient catalytic functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves high conversion rates of dimethoxy methane to dimethyl carbonate with improved selectivity, overcoming the limitations of existing methods by maintaining the stability of the organic compound during decomposition and optimizing catalyst performance.
Implementation Method 1
bringing one or more hydrocarbons into contact with a source of oxygen in the presence of a radical initiator and a catalyst
Implementation Method 2
The catalyst comprises an organic metal complex located on a catalyst support, and is obtained by partial decomposition of the organic metal complex
Implementation Method 3
hydrocarbon oxidation process comprising bringing one or more hydrocarbons into contact with a source of oxygen
Data Source
AI summary
The present invention is related to a hydrocarbon oxidation process. The process comprises bringing one or more hydrocarbons into contact with a source of oxygen in the presence of a radical initiator and a catalyst. The catalyst comprises an organic metal complex located on a catalyst support, and is obtained by partial decomposition of the organic metal complex. For example, the process can be used to produce dimethyl carbonate from dimethoxy methane. The invention is also related to a partially decomposed catalyst that comprises a silica support and an organic metal complex, wherein at least 5% of the organic compound remains in the catalyst. The organic metal complex comprises an organic compound and a metal-based compound wherein the metal is selected from copper, nickel, and combinations thereof. The invention is also related to a process for manufacturing of a catalyst comprising mixing L-arginine, a Cu-based compound, water, and optionally another metal-based compound to form a solution; impregnating the solution onto a silica support to form a catalyst precursor; and partially decomposing the L-arginine to form the catalyst so that at least 5% of L-arginine remains in the catalyst.